MAnufacturing Process

1. Curriculum Development
of Master’s Degree Program in
Industrial Engineering for Thailand Sustainable Smart Industry
P. Koomsap
Course 12: Additive Manufacturing for Industry 4.0
Developer: Pisut Koomsap
Lecture 1 – Teaching material (T)

2. 1. Additive Manufacturing Basic Concepts and processes
• Additive Manufacturing workflow
• Benefits & Limitations of Additive Manufacturing
• Applications of 3D printing (Aerospace, Automotive, Robotics,
Tooling, Healthcare,
• Design, Education etc.)
• Main technologies (ISO/ ASTM DIS 52900:2018)

3. Textbooks
C K Chua, K F Leong, and C.S. Lim, Rapid Prototyping: Principles and
Applications, 2nd Edition, World Scientific, 2003
K.G Cooper, Rapid Prototyping Technology: Selection and Application,
Marcel Dekker, 2001
P.D Hilton, and P.F. Jacobs, Rapid tooling : technologies and industrial
applications, Marcel Dekker, 2000
W.M. Steen, Laser Material Processing, 2nd Edition, Springer, 1998

4. Prototyping
A process of developing an approximation of the
product along one or more dimensions of interest
Purposes of Using Prototypes
• Learning: Will it work?
• Communication: Look&Feel
• Integration: Components work together
• Milestones: Achievement

5. •The degree to which they are physical
• Physical Prototypes
• Analytical Prototypes
• The degree to which they implement the
products’ attributes
• Comprehensive Prototypes
• Focused Prototypes
Types of Prototypes

6. Focused Comprehensive
Physical
Analytical
Not generally
feasible
Alpha Prototype
Beta Prototype
Final Product
Part Prototype
Equation Modeling
Simulation

7. Types of Prototypes
Focused Analytical
Focused Physical
Comprehensive
Physical
Learning
Communi
cation
Integration Milestones
Appropriateness of Different Types of Prototypes for
Different Purposes

8. Principles of Prototyping
• Analytical prototypes are generally more flexible
than physical prototypes
• Physical prototypes are required to detect
unanticipated phenomena
• A prototype may reduce the risk of costly iterations
• A prototype may expedite other development steps
• A prototype may restructure task dependencies

9. Planning for Prototypes
1. Define the purpose of the prototype
2. Establish the level of approximation
of the prototype
3. Outline the experimental plan
4. Create a schedule for procurement,
construction, and test

10. Laser Cutting
Waterjet Cutting
EDM
EB
CNC machining
Subtractive Additive
SLA,
SLS,
FDM,
Direct Casting
LOM
Laser
Bending
Electromagnetic Forming,
Adaptive Die Casting,
Casting,
Forging
Formative
Prototype
Fabrication
Techniques

11. 1950
PC
NC Laser
Robot
CAD
RP
1940
1960
1970
1980
1990
2000
CNC
Technology
RP
Techniques
SLA
LOM
SLS
FDM
Prototyping Manual Virtual Rapid

12. What is Additive Manufacturing?
• Additive Manufacturing is a method in which the part is created
by a layer- additive process.
• Using a specialized software, a 3-D CAD model is cut into very
thin layers or cross-sections.
• Then, depending on the specific method used (sintering, fused
deposition, etc), the AM machine constructs the part layer by
layer until a solid replica of the CAD model is generated.
• The advantages of this process is clear: development of
physical models can be accomplished in significantly less time
as compared to the machining process.
http://www.caip.rutgers.edu/RP_Library/process.html

13. Commonly Used Terms for Additive Manufacturing
• Rapid Prototyping (RP)
• Direct CAD Manufacturing
• Desktop Manufacturing
• Instant Manufacturing
• CAD Oriented Manufacturing
• Layer Manufacturing
• Material Deposit Manufacturing
• Material Addition Manufacturing
• Solid Freeforming

14. Why Rapid Prototyping?
Machining is a subtractive process, beginning with a solid piece
of stock. The machinist must carefully remove material until the
desired geometry is achieved. For complex part geometries,
this is an exhaustive, time consuming, and expensive process.
Some parts are even too complex to be machined.
http://www.caip.rutgers.edu/RP_Library/process.html

15. Concept
Development
System-Level
Design
Detail
Design
Testing &
Refinement
Production
Ramp-Up
Concept
Development
System-Level
Design
Detail
Design
Production
Ramp-Up
Testing &
Refinement
AM for Product Development Process

16. Input
• Physical Objects
• CAD Models
• STL Files
• Sliced Model Files
Material
Paper, Resins, Nylon, ABS,
Wax, metals, ceramics
•Liquid
•Powder
•Solid
Method
• Photocuring
• Cutting&Gluing
• Melting&Solidifying
• Binding
Applications
• Design
•Engineering, Analysis&Planning
•Manufacturing&Tooling
RP

17. Create a CAD model of the design
Convert the CAD model to
STL format
Slice the STL file into layers
Construct the physical model
layer by layer
Clean and finish the model
Basic Steps of AM Processes
Computed Tomography
Scan
• RP requires a closed
volume of the model
• What you see may
not be what you get
The tessellated model

18. Advantages of AM
• Reduce product development time and cost
• Get products to market sooner
• Enhance communications between marketing,
engineering, manufacturing, and purchasing
• Present physical model at critical design reviews
• Perform functional prototype testing before
committing to tooling
• Generate precise production tooling

19. Issues in Layered-Based Manufacturing
• Staircase effect
• Layer thickness
• Accuracy
• Part orientation
• Support Structures

20. AM Processes
Material Basic Process Process Name
Solid
Laminated Object Manufacturing
(LOM)
Fused Deposition Manufacturing
(FDM)
Gluing Sheets
Melting+Solidification
Powder
Selective Laser Sintering
(SLS)
3D Printing
Material powder
Material+Binder
Liquid
Solid Ground Curing
(SGC)
Stereolithography
(SLA)
Liquid
Polymerization
Steen, Laser Material Processing

21. Applications of AM
Design
• CAD model verification
• Visualizing objects
• Proof of concept
• Market and presentation application
Engineering Analysis and Planning
• Form and fit
• Stress analysis
• Mock-up parts
• Pre-production parts
• Diagnostic and surgical operation planning

22. Applications of AM
Manufacturing and Tooling
• Tooling mold parts (soft tooling and hard tooling)
• Casting
• EDM electrodes
• Master models
Industries
• Aerospace
• Jewelry
• Consumer electronics
• Automotive
• Biomedical
• Tableware